Methods of producing structurally reinforced thermoplastic-fabric composite contruction material that are moldable

ABSTRACT

Bound and structurally reinforced thermoplastic-fabric composite construction materials, that are moldable, are described, comprising a structurally reinforced multilayer bound together in a binding process. A barrier fabric layer, and/or a decorative layer, may also be included in order to produce or vary decorative, and/or other effects. The structurally reinforced multilayer is made from a thermoplastic resin system and at least one fabric layer containing reinforcing fibers. Reinforcing fibers are introduced into components of the structurally reinforced multilayer, within the fabric layers, and may also be comingled with or layered into the thermoplastic resin system before addition to the fabric.

This application is a divisional of application Ser. No. 07/766,516,filed Sep. 27, 1991 now U.S. Pat. No. 5,344,687.

BACKGROUND OF THE INVENTION

The present invention relates to novel bound materials.

The present invention also relates to novel bound fabrics andthermoplastic materials, and to the methods of constructing and bindingthem.

The present invention relates to novel bound and structurally reinforcedthermoplastic-fabric composite construction materials, which may bedecorative or nondecorative, and are readily moldable.

The problem of mating rigid and semi-rigid structural and decorativetextile components, such that products capable of being further machineprocessed result, spans several different technical fields. Essentially,production of structurally sound textiles comprising fibers, yarns andfabrics with appropriate finishes for further molding has been a longstanding problem. As such, attempts have been made in which layers offibers have been combined with an assortment of other structuralelements to form the needed composite construction material. Forexample, the manufacture of composite construction materials comprisingreinforcing fibers of filament enclosed in matrices of thermosettingpolymers suffer from storage problems because of their finite shelflives. Thermosetting polymers also harden permanently once heated,precluding further molding of the composite construction materialsproduced therefrom.

In contrast, thermoplastic resin systems do not have storage problems,since they have high molecular weights and are additionallythermoformable, so that they can be worked many times after theirinitial molding at temperature.

However, there are difficulties in producing a composite constructionmaterial which comprises reinforcing fibers within a matrix ofthermoplastic resin. One route of manufacture entails impregnating thereinforcing fibers with a solution of the thermoplastic resin system ina suitable solvent. The solvent is evaporated, and molding is performedto provide the resulting composite construction material. Compositeconstruction materials manufactured by such a method suffer from severalmajor disadvantages. For instance, it is very difficult to completelyevaporate the solvent. Some trapping of solvent may occur, resulting ina somewhat porous composite construction material. Porosity reducesstrength and may lead to accelerated thermal degradation at elevatedtemperatures. Another disadvantage is that it is not usually possible toaccurately monitor the amount of thermoplastic resin system impregnatedinto the filaments. Some usually runs off of the filaments resulting ina final thermoplastic resin system content less than anticipated.

An additional disadvantage of known products of the manufacture ofcomposite construction materials has been well documented. Whencomposite construction materials comprising layers of fabric arereinforced with thermoplastic resin system, much dead, or inert, spaceis often created within the composite. These spaces reduce the value ofthe composite material produced. These problems are often a function ofthe methods utilized to bind together component parts of the compositeconstruction material.

In order to overcome the difficulty involved in joining layers of fabricand the necessary thermoplastic reinforcement layers, a systematiccombination of fabric layers, thermoplastic resin system, and otherneeded layers, is required, such that the components of resultingcomposite construction materials are readily joinable. In so doing, themethods used to bind these composite construction materials, must notadversely effect the properties sought in their creation.

Various materials have previously been used as liners for automotiveinteriors, but there is an increasing demand for liner materials whichcan be further machined, preformed, molded, and readily installed, whichalready have appropriate decorative, structural and molding properties.

While the manufacture of internal furnishing materials for vehicles,houses and the like can be accomplished by subjecting a sheet of plasticto heat and forming solid structures having various curved surfaces, theformed construction material of a plastic sheet alone, has defects suchas a flat appearance and a cold and hard feel. To remedy this defect,methods of binding pieces of cloth onto the surfaces of the plasticsheets alone have been adopted. However, due to the insufficiencies intextural stretching of the cloth or in elongation of the fiber or theyarn which constitutes the cloth, it is necessary to cut and sew thecloth according to the pattern beforehand, and then bind the cloth andthe plastic sheet together, in order to bind the cloth sufficientlyalong the resulting curved surface. Not only are these stepsdisadvantageous in the process, but also the appearance of the finishedcomposite construction material formed has low commercial value.

In order to improve appearance and structure, attempts have been made tobind the cloth and the plastic sheet, and then produce integrated formedproducts. However, such processes have problems in requiring excessivepressure and temperature for forming, which causes deformation to theresulting composite construction material. These defects result from thelarge deformation stress and the small thermoplastic property of thecloth under the forming conditions. When heat is exerted at a sufficienttemperature to enable the cloth to be subjected to heat forming, thecloth is molded under pressure, and changes its fiber form andrecovering property. This results in extreme alteration of appearanceand structure, and low decorative or finished value.

Alternate methods of composite construction material manufacture, oftengenerate as many operating constraints as they eliminate, and the priorart is replete with attempts to acquire specific properties inthermoplastic composite construction materials, through creativemanipulation and substitution of their component materials. When bothstructural and decorative properties are sought, it is often appropriateto employ methods of plastics fabrication in combination with mechanicalalterations. Intermediate plastic forms have been efficiently used forthese purposes.

The present invention is designed to provide bound and structurallyreinforced thermoplastic-fabric composite construction materials, thatare moldable. They may be produced in a one-pass process using bindingmeans, and may have decorative or other nondecorative elements, as well.

The materials produced by the present invention, overcome the problemsin conventional practice, by disposing a series of fabric layerscontaining structural reinforcement fibers, about a thermoplastic resinsystem, introduced as powder, film, or yarn, which is combined bybinding means employing stitch yarns, which will not melt during heatingand molding.

The resulting bound and structurally reinforced thermoplastic-fabriccomposite construction materials, are moldable, and demonstrate astructural uniformity and homogeneity, heretofore undisclosed in theart. This material is then suitable for further ready molding, and/orpre-forming, to yield a structurally reinforced thermoplastic-fabriccomposite construction material product. This product is then furthermoldable, even in its decorative form. An alternate preferred embodimentof the present invention employs stitch yarns which melt, or transform,during molding to create, a finished product having enhanced decorativeappeal.

SUMMARY OF THE INVENTION

An objective of the present invention is to provide bound andstructurally reinforced thermoplastic-fabric composite constructionmaterials, that are moldable, yielding structural and decorative valuesand properties appropriate to the creation of a composite decorativereinforced fabric product, with the utilization of binding means for theattachment of the component composite layers.

Another objective of the present invention, is to provide a bound andstructurally reinforced thermoplastic-fabric composite constructionmaterial, with little or no decorative elements, where the desiredproperties can be generated through the use of a barrier fabric layer,or without the use of additional layers.

A further objective of the present invention, is to provide a bound andstructurally reinforced thermoplastic-fabric composite constructionmaterial, with an incorporated final decorative fabric layer, allowingthe finished molded structural composite product to require no paintingor other surface finishings.

Still another objective of the present invention, is to provide a boundand structurally reinforced thermoplastic-fabric composite constructionmaterial, employing stitch yarns which melt during molding., to create afinished product with enhanced decorative appeal.

These and still further objectives of the present invention, will becomeapparent hereinafter.

Bound and structurally reinforced thermoplastic-fabric compositeconstruction materials, that are moldable are described, comprising astructurally reinforced multilayer component, made from a thermoplasticresin system incorporating reinforcing fibers, introduced into thestructurally reinforced multilayer by means of a fabric layer.Additionally, reinforcing fibers may also be present within thethermoplastic resin system itself. The structurally reinforcedmultilayer, and any additional layers, such as a barrier fabric layerand/or a decorative layer, are bound together in a binding process.

Additionally, a method is described for making the bound andstructurally reinforced thermoplastic-fabric composite constructionmaterials, that are moldable, by binding the structurally reinforcedmultilayer together with any associated layers, utilizing conventionalstitching, knitting, sewing, and ultrasonic binding, or the like bindingtechniques.

The bound and structurally reinforced thermoplastic-fabric compositeconstruction material, that is moldable, is produced in roll formsuitable for preforming and/or molding.

The bound and structurally reinforced thermoplastic-fiber compositeconstruction materials, that are moldable, of the present invention haveutility in the manufacture of automotive door panels, stackablefurniture items, or other industrial applications, contingent upon themating together of rigid and semi-rigid structural parts and panelsand/or decorative panels and parts.

In summary, and in accordance with the above discussion, the foregoingobjectives are achieved in the following embodiments.

1. A bound and structurally reinforced thermoplastic-fabric compositeconstruction material that is moldable, comprising a structurallyreinforced multilayer, said structurally reinforced multilayer, furthercomprising at least one thermoplastic resin system layer, and at leastone fabric layer containing reinforcing fibers.

2. A bound and structurally reinforced thermoplastic-fabric compositeconstruction material, as described in paragraph 1, wherein saidstructurally reinforced multilayer, further comprises a plurality offabric layers.

3. A bound and structurally-reinforced thermoplastic fabric compositeconstruction material, as described in paragraph 1, wherein saidthermoplastic resin system layer, further comprises reinforcing fibers,selected from the group consisting of textile and nontextile yarn,filament strands and monofilaments.

4. A bound and structurally reinforced thermoplastic-fabric compositeconstruction material, as described in paragraph 1, wherein said fabriclayer, further comprises reinforcing fibers selected from the groupconsisting of glass, graphite, KEVLAR fibers, textile, chopped strandmat and continuous strand mat.

5. A bound and structurally reinforced thermoplastic-fabric compositeconstruction material, as described in paragraph 1, wherein saidstructurally reinforced thermoplastic-fabric composite constructionmaterial is stitch-bound.

6. A structurally reinforced thermoplastic-fabric composite constructionmaterial, as described in paragraph 1, wherein said structurallyreinforced thermoplastic-fabric composite construction material is notbound.

7. A bound and structurally reinforced thermoplastic-fabric compositeconstruction material, as described in paragraph 5, wherein thestitch-binding means are selected from the group consisting of knitting,sewing, and stitching.

8. A bound and structurally reinforced thermoplastic-fabric compositeconstruction material, as described in paragraph 4, wherein said fabriclayer further comprises said reinforcing fibers arranged in any desiredorientation.

9. A bound and structurally reinforced thermoplastic-fabric compositeconstruction material, as described in paragraph 2, wherein saidplurality of fabric layers, further comprise at least one reinforcingfiber selected from the group consisting of glass, graphite, and KEVLARfibers, or the like fiber.

10. A bound and structurally reinforced thermoplastic-fabric compositeconstruction material, as described in paragraph 2, wherein saidplurality of fabric layers further comprising said reinforcing fibers.

11. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, that is moldable,which comprises introducing a thermoplastic resin system to at least onefabric layer, which contains reinforcing fibers, to form a structurallyreinforced multilayer, and binding together said structurally reinforcedmultilayer with stitch yarn on at least one stitch-binding means,selected from the group consisting of stitching, knitting, and sewingmeans.

12. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, as described inparagraph 11, which further comprises introducing a barrier fabric layeradjacent to said structurally reinforced multilayer, and binding saidbarrier fabric layer with said structurally reinforced multilayer.

13. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, as described inparagraph 11, which further comprises introducing at least one barrierfabric adjacent to said structurally reinforced multilayer, introducinga decorative layer adjacent to said barrier fabric layer, such that saidbarrier fabric layer is positioned between said structurally reinforcedmultilayer and said decorative layer, and binding together saiddecorative layer, said barrier fabric layer and said structurallyreinforced multilayer.

14. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, as described inparagraph 11, which further comprises introducing at least onedecorative layer adjacent to said structurally reinforced multilayer,and binding together said decorative layer and said structurallyreinforced multilayer.

15. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, as described inparagraph 11, which further comprises heating said structurallyreinforced multilayer in order to bond said layers of said structurallyreinforced multilayer, prior to binding said structurally reinforcedmultilayer with said stitch yarn.

16. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, as described inparagraph 11, wherein said stitch yarn, further comprises a fiber havinga sufficiently higher melting point, than that of the thermoplasticresin system, in order to prevent said stitch yarn from melting duringthe molding process and applying heat to said thermoplastic-fabriccomposite.

17. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, as described inparagraph 11, wherein said stitch yarn further comprises a textile fiberselected from the group consisting of KEVLAR fibers, nylon, glass andpolyester.

18. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, as described inparagraph 11, which further comprises introducing said thermoplasticresin system in a powder form, to at least one fabric layer, and heatingsaid thermoplastic resin system for attachment to said reinforcingfibers of said structurally reinforced multilayer, prior to said bindingwith said stitch yarn.

19. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, as described inparagraph 11, wherein said thermoplastic resin system, introduced intosaid structurally reinforced multilayer, is at least one form, selectedfrom a group consisting of powder, film, nonwoven fabrics, fibers, yarn,filament and monofilament.

20. A method to construct a bonded and structurally reinforcedthermoplastic-fabric composite construction material, as described inparagraph 11, wherein said thermoplastic resin system that is introducedinto said structurally reinforced multilayer, further comprises at leastone form of reinforcing fiber selected from the group consisting ofyarn, filament strands and monofilaments, wherein said thermoplasticresin system being layered with said reinforcing fibers.

21. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, as described inparagraph 11, wherein said thermoplastic resin system that is introducedinto said structurally reinforced multilayer, further comprises at leastone form of reinforcing fiber selected from the group consisting ofyarn, filament strands and monofilaments, wherein said thermoplasticresin system being comingled with reinforcing fiber strands.

22. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, as described inparagraph 11, wherein said thermoplastic resin system is introduced inthe form of a plurality of thermoplastic resin system layers.

23. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, as described inparagraph 11, wherein said decorative layer and said structurallyreinforced multilayer are impregnated with said thermoplastic resinsystem.

24. A product, as produced by the method described in paragraph 11,comprising a bound and structurally reinforced thermoplastic-fabriccomposite construction material that is moldable.

25. A product, as produced by the method described in paragraph 12,comprising a bound and structurally reinforced thermoplastic-fabriccomposite construction material that is moldable.

26. A product, as produced by the method described in paragraph 13,comprising a bound and structurally reinforced thermoplastic-fabriccomposite construction material that is moldable.

27. A product, as produced by the method described in paragraph 14,comprising a binded and structurally reinforced thermoplastic-fabriccomposite construction material that is moldable.

28. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, that is moldable,as described in paragraph 11, further comprising, wherein prior tobinding, a barrier fabric layer is introduced from a roll; said barrierfabric layer being in the form of at least one selected from the groupconsisting of film, nonwoven cloth, and flexible cloth; said barrierfabric layer density being sufficient to prevent melted thermopasticresin liquids from migrating through, yet of a nature that would allowstitching needles or the like mechanical binding means to pierce throughand bind said barrier fabric layer to said reinforcing multilayerbeneath; said barrier fabric layer being insoluble in the thermoplasticresin system utilized; and said barrier fabric layer remainingsubstantially unchanged.

29. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material that is moldable,as described in paragraph 12, wherein prior to binding, a barrier fabriclayer is introduced from a roll; said barrier fabric layer being in theform of at least one selected from a group consisting of film, nonwovencloth, woven cloth and flexible cloth; said barrier fabric layer beingdense enough to prevent melted thermoplatic resins liquids frommigrating through, yet of a nature that would allow stitching needles orother mechanical binding means, to pierce through and bind said barrierfabric layer to the reinforcing multilayer beneath; said barrier fabriclayer being insoluble in the thermoplastic resin system utilized; saidbarrier fabric layer having a melting point sufficiently above themelting point of the thermoplastic resin system, such that when theresultant product is heated, liquifying said thermoplastic resin system,said barrier fabric layer remains substantially entirely unchanged.

30. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, as described inparagraph 12, wherein the stitch yarn melts, and allows for a controlledamount of resin to penetrate through said barrier fabric layer,sufficient to adhere said decorative layer to said barrier fabric layerand the structurally reinforced multilayer adjacent to the barrierfabric layer once molding is completed.

31. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, as described inparagraph 12, wherein said decorative layer comprising a desired fabricis introduced, said decorative layer being pierceable with stitchingneedles or other mechanical binding means, which will allow a stitchingmachine or other binding means to bind said layers, said decorativelayer having a melting point sufficiently above the melting point ofsaid thermoplastic resin system.

32. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, as described inparagraph 13, wherein said decorative layer comprising a desired fabricis introduced, said decorative layer being pierceable with stitchingneedles or other mechanical binding means, which will allow a stitchingmachine, or other binding means, to bind said layers, said decorativelayer having a melting point sufficiently above the melting point ofsaid thermoplastic resin system utilized.

33. A method of producing molded products from the bound andstructurally reinforced thermoplastic-fabric composite constructionmaterials, as described in para. 24, further comprising cutting apattern of said construction materials, exposing said pattern ofconstruction material to a thermoforming process, wherein the bound andstructurally reinforced thermoplastic-fabric composite constructionmaterial is heated to a level wherein said thermoplastic resin systemwill melt and contact said reinforcing fiber as the thermoplastic resinsystem is simultaneously dimensionally shaped, cooling and moldseparating, whereupon the resin hardens, whereby the bound andstructurally reinforced thermoplastic-fabric composite constructionmaterial becomes rigid, and is then removed from the mold.

34. A method of producing molded products from the binded andstructurally reinforced thermoplastic-fabric composite constructionmaterials, as described in para. 25, further comprising cutting apattern of said construction materials, exposing said pattern ofconstruction material to a thermoforming process, wherein the binded andstructurally reinforced thermoplastic-fabric composite constructionmaterial is heated to a level wherein said thermoplastic resin systemwill melt and contact said reinforcing fiber as the thermoplastic resinsystem is simultaneously dimensionally shaped, cooling and moldseparating, whereupon the resin hardens, whereby the bound andstructurally reinforced thermoplastic-fabric composite constructionmaterial becomes rigid, and is then removed from the mold.

35. A method of producing molded products from the bound andstructurally reinforced thermoplastic-fabric composite constructionmaterials, as described in para. 26, further comprising cutting apattern of said construction materials, exposing said pattern ofconstruction material to a thermoforming process, wherein the bound andstructurally reinforced thermoplastic-fabric composite constructionmaterial is heated to a level wherein said thermoplastic resin systemwill melt and contact said reinforcing fiber as the thermoplastic resinsystem is simultaneously dimensionally shaped cooling and moldseparating, whereupon the resin hardens, whereby the bound andstructurally reinforced thermoplastic-fabric composite constructionmaterial becomes rigid, and is then removed from the mold.

36. A method of producing molded products from the bound andstructurally reinforced thermoplastic-fabric composite constructionmaterials, as described in para. 27, further comprising cutting apattern of said construction materials exposing said pattern ofconstruction material to a thermoforming process, wherein the bound andstructurally reinforced thermoplastic-fabric composite constructionmaterial is heated to a level wherein said thermoplastic resin systemwill melt and contact said reinforcing fiber as the thermoplastic resinsystem is simultaneously dimensionally shaped, cooling and moldseparating, whereupon the resin hardens, whereby the bound andstructurally reinforced thermoplastic-fabric composite constructionmaterial becomes rigid, and is then removed from the mold.

37. A bound and structurally reinforced thermoplastic-fabric compositeconstruction material, suitable as a remoldable decorative product,comprising: a structurally reinforced multilayer, said structurallyreinforced multilayer further comprising fabric layers, a thermoplasticresin system, a barrier fabric layer and a decorative layer; saidthermoplastic resin system, comprising a thermoplastic resin systemlayer; said fabric layers further comprising reinforcing fibers; andsaid bound and structurally reinforced thermoplastic-fabric compositeconstruction material being stitch-bound.

38. A method to construct a bound and structurally reinforcedthermoplastic-fabric composite construction material, suitable forconstructing remoldable decorative products, comprising: forming astructurally reinforced multilayer, by introducing a thermoplastic resinsystem into fabric layers, said fabric layers further comprisingreinforcing fibers; placing a barrier fabric layer adjacent to saidstructurally reinforced multilayer; placing a decorative layer adjacentto said barrier fabric layer.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the present invention may be more fully and readilyunderstood, and, further, that all the features thereof may be betterappreciated, the present invention will now be described by way ofpreferred examples, with reference to the accompanying drawings.

FIG. 1 is an elevated perspective view of a section of the components ofa preferred embodiment of the structurally reinforcedthermoplastic-fabric composite construction material, that is moldable,of the present invention, prior to binding.

FIG. 2 is an elevated perspective view of a section of the components ofan alternate preferred embodiment of the structurally reinforcedthermoplastic-fabric composite construction material, that is moldable,of the present invention, prior to binding.

FIG. 3 is a perspective view of a section of the components of thepreferred embodiment, of a bound and structurally reinforcedthermoplastic-fabric composite construction material, that is moldable,of the present invention, as shown in FIG. 1, with all of the componentsbinded with stitch yarn.

FIG. 4 is a perspective view of a section of the components of thepreferred embodiment, of a bound and structurally reinforcedthermoplastic-fabric composite construction material, that is moldable,of the present invention, as shown in FIG. 1, wherein all of thecomponents are bound, with the stitch yarn dissolved or melted.

DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE PRESENT INVENTION

FIG. 1, is an elevated perspective view of a section of the componentsof a preferred embodiment of the structurally reinforcedthermoplastic-fabric composite construction material, that is moldable,of the present invention, prior to binding. The structurally reinforcedthermoplastic-fabric composite construction material, that is moldable,prior to binding, is depicted here generally as 10A. The structurallyreinforced multilayer 10, comprises single or multiple fabric layerscontaining reinforcing fibers, and a thermoplastic resin system. Thethermoplastic resin system is not numbered in any figure depictedherein, since it is the starting material, introduced to eventuallycomprise the thermoplastic resin system layer 16. In the preferredembodiment of FIG. 1, the structurally reinforced multilayer 10 isillustrated as having fabric layers 22 and 24, respectively, below andabove the thermoplastic resin system layer 16. These fabric layers 22and 24, are constructed on a textile machine, with fiber orientationswhich may range from unidirectional single layer fiber orientations, tounidirectional multiple-layered fiber orientations, to combinations offibers and fiber orientations, in any conceivable angle.

Fabric layers 22 and 24, shown below and above the thermoplastic resinsystem layer 16, are further comprised of reinforcing fibers 12.Reinforcing fibers 12 may consist of textile, and/or nontextile fibers.Such nontextile, and/or textile, reinforcing fibers of high strength,such as glass, graphite, KEVLAR fibers, or the like, may be employed.The orientations of these nontextile reinforcing fibers 12, may rangefrom unidirectional single layer fiber orientations, to unidirectionalmultiple-layered fiber orientations, to combinations of fibers and fiberorientations, in any conceivable angle.

Textile reinforcing fibers 12, are typically, glass, nylon, polyester,graphite, cotton, wool, rayon, or the like. These textile reinforcingfibers 12, may be in the form of either random or oriented fiberdistribution, or continuous mat. Fabric layers 22 and 24, may also be ofhybrid reinforcing fiber 12 construction, with fiber blends in anyorientation, layer, or angle, to optimize material and productproperties. Also, textile and nontextile reinforcing fibers 12, may becombined in any fabric layer, or layers 22 or 24, in any of the abovefiber orientations.

Prior to binding the aforementioned structurally reinforced multilayer10, a thermoplastic resin system is introduced, which ultimately becomesthe thermoplastic resin system layer 16, which becomes part of thestructurally reinforced multilayer 10 along with the adjacent bottom andtop fabric layers 22 and 24, respectively. The thermoplastic resinsystem may be introduced to the structurally reinforced multilayer 10,in powder form, which may then be heated for attachment to thereinforcing fibers 12, of the fabric layers 22 and 24, thereby providingstructural reinforcement. The thermoplastic resin system, may also beintroduced as a thermoplastic film layer 16, being fed to become part ofthe structurally reinforced multilayer 10, from roll goods.

The thermoplastic resin system, that is introduced to the fabric layers22 and 24, may include reinforcing fibers 14, such that thethermoplastic resin system layer 16 will contain textile or nontextilereinforcing,fibers 14. The thermoplastic resin system may be introducedwith strands of reinforcing fiber 14, of a fibrous nonwovenconstruction, or with strands of reinforcing fiber 14, such as yarn,filaments, straws or monofilaments, such that the thermoplastic resinsystem is layered with the reinforcing fiber 14 strands. Alternatively,the thermoplastic resin system may be comingled with the reinforcingfibers 14, by plying or twisting, or non-plying or non-twisting, thereinforcing fibers 14, with the thermoplastic resin system, or bycomingling the reinforcing fibers 14 prior to the yarn, strand, roving,or the like, construction.

In the preferred embodiment as depicted in FIG. 1, the structurallyreinforced multilayer 10, with the thermoplastic resin system layer 16,disposed adjacent to, and between the fabric layers 22 and 24, isbordered on the top by an adjacent barrier fabric layer 18. This barrierfabric layer 18, is designed to confine the thermoplastic resin system,which may otherwise seep through the adjacent fabric layer 24, to thedecorative layer 20, during heating and molding. This barrier fabriclayer 18, may be introduced from a roll in the form of a film, anonwoven, or any flexible fabric barrier, dense enough to prevent liquidthermoplastic resins from migrating through, yet of a nature that wouldallow stitching needles, or other mechanical binding means to piercethrough and bind the barrier fabric layer 18, to the structurallyreinforced multilayer 10 beneath.

Being adjacent to the top-most fabric layer 24, as well as situatedabove the thermoplastic resin layer 16, the barrier fabric layer 18,also serves as a barrier, or retainer, between the reinforcing fibers 12of the fabric layer 24, and the final or outer-most surface decorativelayer 20.

The chemistry of the barrier fabric layer 18, should also be such thatit is not soluble in the thermoplastic resin system. It shouldfurthermore have a melting point sufficiently above the melting point ofthe thermoplastic resin system. This is required, so that when thematerial or product, is heated to liquify the thermoplastic resinsystem, the barrier fabric layer 18, will remain substantiallyunaffected.

The decorative layer 20, serves as the final or outer layer of thestructurally reinforced thermoplastic-fabric composite constructionmaterial 10A, that is moldable, of the present invention, and may becomprised of woven or nonwoven fabric as desired, to enhance theappearance of the final material or product. The decorative layer 20,may also be situated on both sides of the structurally reinforcedmultilayer 10, in order to achieve a two-sided decorative reinforcedcomposite material. The preferred embodiment of the present inventionwill be pierceable with conventional stitching needles or othermechanical binding means, as well as to allow the stitching machine orother binding means to combine or bind all component layers described.

It should be noted that the term "binding," as used throughout, isgenerally interchangeable with the term "bonding." Generally, the term"binding" is used when referring to attachment by mechanical means, suchas stitching materials or layers together, etc. The term "binding," isherein used to distinguish from the meaning of the term "bonding," whichgenerally includes attachment by a chemical process.

The preferred embodiment of decorative layer 20, usually employs aneedle felt, or the like, due to the ease of stitching and the abrasiveproperties associated therewith. For example, the decorative layer 20,could be in the form of a printed nonwoven fabric with a camouflagedesign, allowing the finished molded, bound and structurally reinforcedthermoplastic-fabric composite construction material, to require neitherpainting nor further surface finishing. Further examples involve use ofa woven or embossed cloth for the decorative layer 20, which yields amaterial having a textured surface. The decorative layer 20, whenincorporated, must have melting properties suitably higher than that ofthe thermoplastic resin system, used to form the structurally reinforcedmultilayer 10.

FIG. 2, is an elevated perspective view of a section of the componentsof an alternate preferred embodiment of the structurally reinforcedthermoplastic-fabric composite construction material, that is moldable,of the present invention, prior to binding. This structurally reinforcedthermoplastic-fabric composite construction material, prior to binding,is depicted here generally as 10B. This alternate preferred embodiment,has all of the same components as in the preferred embodiment shown inFIG. 1, with the exception that the barrier fabric layer 18 is omitted,and the thermoplastic resin system layer 16, does not therein containreinforcing fibers 14.

In this alternate preferred embodiment, i.e. 10B, the barrier fabriclayer 18, is eliminated and, the decorative layer 20, is introducedimmediately adjacent to the fabric layer 24, of the structurallyreinforced multilayer 10. During the molding process, this decorativelayer 20, is impregnated with the thermoplastic resin system, of thestructurally reinforced multilayer 10.

FIG. 3, is a perspective view of a section of the components of thepreferred embodiment, of a bound and structurally reinforcedthermoplastic-fabric composite construction material, that is moldable,of the present invention, as shown in FIG. 1, except, not showingreinforcing fibers 14, and with all of the components bound with stitchyarn. This bound and structurally reinforced thermoplastic-fabriccomposite construction material, that is moldable, is depicted in FIG. 3generally as 10C. The bound and structurally reinforcedthermoplastic-fabric composite construction material, that is moldable,i.e. 10C, is herein illustrated in bound form, wherein all layers, i.e.12, 16, 24, 18 and 20, are bound together with stitch yarn 26. Thebarrier fabric layer 18, as above described, serves as a barrier toprevent thermoplastic resin system impregnation of the decorative layer20.

After all component layers of the structurally reinforcedthermoplastic-fabric composite construction material, that is moldable,i.e. here seen as 10C, are arranged as desired, the component layers areattached together via traditional stitching, knitting, sewing,ultrasonic binding, or the like, binding means, along the stitchingarea. All of the component layers are bound together with a stitch yarn26 made from a fiber having sufficiently higher melting point ortemperature resistance, than that of the thermoplastic resin system, inorder to prevent the stitch yarn 26, from melting during the heating ormolding process. This stitch yarn 26, could be of fibers, such astextile, or nontextile fibers. This bound and structurally reinforcedthermoplastic-fabric composite construction material, that is moldable,i.e., 10C, is now ready for pattern cutting in order to ready it for theheating in the molding process.

A cut pattern can be placed in a thermoforming process, whereupon thetemperature is elevated to a level where the thermoplastic resin system,in either fibrous film, powder or nonwoven form, will melt and wet thereinforcing fibers 12, of fabric layers 22 and 24, at the same time asit is dimensionally shaped, to the shape of the finished bound andstructurally reinforced thermoplastic-fabric composite constructionmaterial, that is moldable, i.e., 10C. The temperature can then bereduced, whereupon free thermoplastic resin will harden and the finishedproduct will turn rigid. The product can then be removed from the mold.The molded, bound structurally reinforced thermoplastic-fabric compositeconstruction material 10C, is also capable of being remolded.

FIG. 4, is a perspective view of a section of the components of thepreferred embodiment, of a bound and structurally reinforcedthermoplastic-fabric composite construction material, that is moldable,of the present invention, as shown in FIG. 1, wherein all of thecomponents are bound, with the stitch yarn 26 dissolved or melted. Thisbound and structurally reinforced thermoplastic-fabric compositeconstruction material, that is moldable, is depicted here generally as10D. In this embodiment, the decorative layer 20, the barrier fabriclayer 18, and the structurally reinforced multilayer 10, are boundtogether by conventional stitching, knitting, sewing, ultrasonicbinding, or the like, binding techniques. However, here the stitch yarn26, has been dissolved or melted in the molding process, in order toprevent it from detracting from the desired appearance of the finishedmaterial, and resulting product, and the stitch yarn 22, is, therefore,not visible in FIG. 4.

The barrier fabric layer 18 may also serve to prevent the thermoplasticresin system from seeping into the decorative layer 20. Alternatively,melting of the stitch yarn 22, may also allow a controlled amount of thethermoplastic resin system to penetrate through barrier fabric layer 18,sufficient to adhere the decorative layer 20, to the barrier fabriclayer 20, and the structurally reinforced multilayer 10, upon heating.

This bound and structurally reinforced thermoplastic-fabric compositeconstruction material, that is moldable, i.e., 10D, may be cut andmolded as above mentioned.

Additionally, it should be noted that although all embodiments describedherein are bound, it is also envisioned that certain embodiments, thatare not bound, may also be constructed by methods of the presentinvention.

The previous detailed description of the preferred embodiments of thepresent invention is presented for purposes of clarity of understandingonly, and no unnecessary limitations should be understood or impliedtherefrom, as all appropriate mechanical and functional equivalents tothe above, which may be obvious to those skilled in the arts pertainingthereto, are considered to be encompassed within the claims of thepresent invention.

What is claimed is:
 1. A method of forming a structurally reinforcedthermoplastic-fabric composite element comprising:providing a fabriclayer which contains reinforcing fibers; introducing a thermoplasticresin to the fabric layer; providing a decorative layer in superimposedspaced relation to the fabric layer; providing a barrier layerinterposed between the fabric layer and the decorative layer; selectingthe barrier layer to have a sufficiently high density to substantiallyprevent the thermoplastic resin from migrating through the barrier layerif the thermoplastic resin is heated; and binding the fabric layer,decorative layer and barrier layer together to form a composite bystitching through the fabric layer, decorative layer and barrier layer.2. The method of claim 1 further comprising heating the fabric layer andthermoplastic resin to a temperature greater than or equal to thesoftening temperature of the thermoplastic resin prior to the bindingstep.
 3. The method of claim 2 further comprising selecting a thread forsaid stitching which has a sufficiently high melting point so that itwill not melt during said heating step.
 4. The method of claim 3 whereinsaid thread comprises a textile fiber selected from the group consistingof KEVLAR, NYLON, glass and polyester fibers.
 5. The method of claim 2further comprising selecting a thread for said stitching which meltsduring said heating step.
 6. The method of claim 1 wherein thethermoplastic resin is introduced in powder form.
 7. The method of claim6 further comprising the step of heating the fabric and thermoplasticpowder to fuse said thermoplastic powder to said reinforcing fibers. 8.The method of claim 1 wherein said thermoplastic resin is introduced inthe form of a material selected from the group consisting of films,non-woven fabrics, discontinuous fibers, yarns, continuous filaments,and monofilaments.
 9. The method of claim 1 wherein said thermoplasticresin is introduced in the form of a plurality of layers.
 10. The methodof claim 1 further comprising selecting the barrier layer from the groupconsisting of films, non-wovens fabrics, woven fabrics and knittedfabrics.
 11. The method of claim 1 further comprising selecting saiddecorative layer and said barrier layer so that each has a melting pointhigher than that of the thermoplastic resin.
 12. The method of claim 1further comprising the step of thermoforming the composite formed by thebinding step.